CN109853133B - Preparation method of mixed fiber cotton pad - Google Patents
Preparation method of mixed fiber cotton pad Download PDFInfo
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- CN109853133B CN109853133B CN201910167205.1A CN201910167205A CN109853133B CN 109853133 B CN109853133 B CN 109853133B CN 201910167205 A CN201910167205 A CN 201910167205A CN 109853133 B CN109853133 B CN 109853133B
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Abstract
The invention discloses a preparation method of a mixed fiber cotton pad, which comprises the following steps: step 1, premixing: putting the low-melting-point fibers and the high-melting-point fibers into an opening carding machine for opening, carding and mixing, and preparing primary mixed cotton; step 2, heating and shaping: put into the mould with the mixed cotton of above-mentioned primary type to compress tightly fixedly, then assemble the mould on high pressure cycle air heater, add the fever design to the mixed cotton of primary type in the mould, specifically do: heating the cavity to 200-280 deg.c for 1-2min, and maintaining at 200-280 deg.c for 1-5min for the whole shaping process of 2-7 min; step 3, demolding finished products: and (3) taking the mold out of the cavity when the temperature of the cavity is cooled to 115-125 ℃, demolding when the temperature of the mold is reduced to 55-65 ℃, and inspecting and warehousing after demolding of finished products. The method can make the fiber cotton pad have short forming time, can be formed in 2-7min, and has good forming effect.
Description
Technical Field
The invention relates to the technical field of bedding articles, in particular to a preparation method of a mixed fiber cotton pad.
Background
At present, mattresses, cushions, pillow cores and the like are generally made of cotton, silk, sponge, chemical fibers or the like, and mainly meet different requirements of different people on heat retention, air permeability, softness, elasticity and the like.
Comparison document 1: the application number is "CN 201310030890.6", the name is "seaweed fiber mat and the preparation method thereof", the preparation process of the fiber mat comprises the following steps: carding and mixing various fibers respectively; laying the mixed fibers into a net with a required thickness by using a lapping machine; needling the laid web into a fibrous mat of predetermined shape; blowing hot air to the fiber mat from top to bottom or from bottom to top to melt the low-melting-point fibers in the net, and using the low-melting-point fibers as an adhesive to bond the unmelted high-melting-point fibers; and blowing cold air to the fiber pad from bottom to top or from top to bottom to cool and shape the melted low-melting-point fiber. According to the preparation process of the fiber mat, the fibers with two different melting points are used as raw materials, and the fibers in the fiber mat are bonded together in a mode of blowing hot air and then blowing cold air on the fiber mat, so that the fiber mat is bonded instead of glue, and the bonding property of the fiber mat is improved. The preparation method of the seaweed fiber mat disclosed in the embodiment of the specification of the patent comprises the following steps: (S110) laying the raw material mixture with a thickness of 5 cm; (S130) penetrating the bicomponent sheath-core fiber with hot air at 180 ℃ by utilizing a hot air penetration technology to melt the sheath of the bicomponent sheath-core fiber; (S140) solidifying the molten bonding fibers by using a cold air penetration technology and cold air at 5 ℃, and bonding the fibers together to obtain the seaweed fiber mat with the thickness of 0.4 cm. However, this solution still presents several problems: (1) in the molding process, when the temperature of the cavity is kept at 140 ℃ of 120-; when the temperature of the cavity is kept at 190 ℃ of 170-; (2) the scheme adopts a needle punching shaping method, and has the disadvantages of complicated steps and poor shaping effect; (3) when the hot air penetration technique is used in the step (S130), the hot air has no pressure, the penetration capability is poor, and the polypropylene fiber filaments cannot be completely melted.
How to improve the forming effect of the mixed fiber cotton pad becomes a problem to be solved urgently.
Disclosure of Invention
The invention aims to overcome the defects of the prior art and provides a preparation method of a mixed fiber cotton pad, so that the fiber cotton pad can be formed in a short time of 2-7min and has a good forming effect.
The invention is realized by the following steps:
the invention aims to provide a preparation method of a mixed fiber cotton pad, which comprises the following steps:
In the step 1, low-melting-point fibers and high-melting-point fibers are required to be added in the forming process, the adding amount of the low-melting-point fibers is controlled to be 10% -30%, and if too many low-melting-point fibers are added, the pillow inner made of the cushion pillow core becomes hard. According to the adding proportion of the low-melting-point fibers, the high-melting-point fibers are correspondingly subtracted, and the overall proportion is kept at 100%. The low melting point fibers serve to connect the high melting point fibers.
Compared with the prior art, the invention has the following advantages and effects:
1. the preparation method of the mixed fiber cotton pad is different from the prior art in that the cavity temperature is heated to 200-280 ℃ from the initial temperature for 1-2min, then the temperature is kept at 200-280 ℃ for 1-5min, and the whole shaping process is 2-7 min; when the temperature of the cavity is cooled to 115-125 ℃, taking the mold out of the cavity, and demolding when the temperature of the mold is reduced to 55-65 ℃, wherein the air pressure of the high-pressure circulating air heater is 1700-2000 Pa; the temperature (200-280 ℃) and the wind pressure (1700-2000Pa) in the range can quickly melt the low-melting-point fiber, simultaneously the high-melting-point fiber is not melted, the forming time of the fiber cotton pad is fast due to the hot wind with pressure, the fiber cotton pad can be formed within 2-7min, the forming effect is good, and the product effect can be optimal only by fully melting and crosslinking the low-melting-point fiber under the premise that the temperature is high and the high-melting-point fiber is not melted after the wind pressure reaches a certain value.
2. According to the preparation method of the mixed fiber cotton pad, the shell of the die adopted in the step 2 is of a closed structure, so that hot air with pressure can only pass up and down, thereby ensuring that high-pressure hot air penetrates through the middle of the shell, and fully melting and crosslinking low-melting-point fibers. The inner cavity of the mould can also be designed into a shape meeting the production requirements, for example: pillow cores, pillow mats (example 3), back cushions, seat cushions (example 1), bed mattresses (example 2), protectors, and the like. The inner cavities with different shapes are matched with different heating and shaping processes (heating temperature and time, cooling temperature and time) simply and quickly.
Drawings
FIG. 1 is a flow chart of a method for making a hybrid fiber cotton mat according to the present invention;
FIG. 2 is a view showing the structure of a mold used in example 1 of the present invention;
FIG. 3 is a view showing the structure of a mold used in example 2 of the present invention;
fig. 4 is a structural view of a mold used in example 3 of the present invention.
Detailed Description
Example 1
1. Fiber carding: before mixing, the low-melting-point fibers and the high-melting-point fibers are respectively carded by a fiber carding machine, wherein the adding weight of the low-melting-point fibers accounts for 10% of the total amount, and the adding weight of the high-melting-point fibers accounts for 90% of the total amount. The low-melting-point fiber is selected from the following brands: korean general korea (yinglong); the types are as follows: 4080 low melting fiber; melting point: 110 ℃; specification: 4D × 51 MM. The high melting point fiber is 15D 64 three-dimensional spiral polyester fiber.
2. Premixing: and putting the low-melting-point fibers and the high-melting-point fibers into an opening carding machine for opening, carding and mixing, and preparing the primary mixed cotton.
3. Heating and shaping: as shown in fig. 2, a cushion mold (the mold comprises a base 1, a shell 2 and a gland 3, the base 1 is provided with a plurality of vent holes, the shell 2 is installed on the base 1, the gland 3 is assembled in the shell 2, the gland 3 is provided with a handle 3-1 convenient to operate, the gland 3 is provided with a group of vent holes, the inner core of the mold is in an octagonal cushion shape, the mixed primary mixed cotton is placed in the mold, the gland 3 is placed on the primary mixed cotton and is compacted by the gland 3, then the gland is propped and compacted by a group of positioning pins (the positions of the positioning pins are set according to the thickness of the cushion, the positions of the cushions with different thicknesses are different), then the mold is placed at the air outlet of a high-pressure circulation air heater, the high-pressure circulation air heater is started, the high-pressure circulation air heater is controlled to heat the cavity from the initial temperature to 280 ℃, the time is 1min, then the temperature is kept for 1min at 280 ℃, and the whole shaping process is2 min; the air pressure of the high-pressure circulating air heater is 1700-2000 Pa; the parameters of the circulating industrial air heater are as follows: 3-500 KW; maximum air volume: 1.8-75M3Min; wind pressure: 100 to 7500 pa; outlet temperature: normal temperature to 350 ℃; inlet temperature: normal temperature to 180 ℃; the device has the advantages of recycling, low heat loss, energy conservation, high efficiency, uninterrupted continuous work, durability and accurate temperature control.
3. And (3) demolding finished products: and (3) discharging the die from the cavity when the temperature of the cavity is cooled to 120 ℃, demoulding when the temperature of the die is reduced to 60 ℃, taking down the die, dismantling the positioning pin, taking down the gland 3, and finally taking out the finished cushion (with the thickness of 20 mm).
Example 2
1. Fiber carding: before mixing, the low-melting-point fibers and the high-melting-point fibers are respectively carded by a fiber carding machine, wherein the adding weight of the low-melting-point fibers accounts for 30% of the total amount, and the adding weight of the high-melting-point fibers accounts for 70% of the total amount. The low-melting-point fiber is selected from the following brands: korean general korea (yinglong); the types are as follows: 4080 low melting fiber; melting point: 110 ℃; specification: 4D × 51 MM. The high melting point fiber is 50% of 15D × 64 three-dimensional spiral polyester fiber and 50% of hemp fiber.
2. Premixing: and putting the low-melting-point fibers and the high-melting-point fibers into an opening carding machine for opening, carding and mixing, and preparing the primary mixed cotton.
2. Heating and shaping: as shown in fig. 3, a mattress mold (the mold includes a base 1, a housing 2 and a gland 3, a plurality of vent holes are provided on the base 1, the housing 2 is installed on the base 1, the gland 3 is assembled in the housing 2, a handle 3-1 convenient for operation is provided on the gland 3, a plurality of vent holes are provided on the gland 3, the inner core of the mold is shaped like a mattress, the mixed primary mixed cotton is put into the mold, the gland 3 is placed on the mixed primary mixed cotton and is compacted by the gland 3, then a set of positioning pins (the positions of the positioning pins are set according to the thickness of the cushion, the positions of the cushion positioning pins with different thicknesses are different) are used, the mold is placed at the air outlet of the high pressure circulation air heater, the high pressure circulation air heater is started, and the high pressure circulation air heater is controlled to make the cavity body have different shapesHeating to 280 ℃ from the initial temperature for 3min, then keeping the temperature at 280 ℃ for 4min, and setting the whole process for 7 min; the air pressure of the high-pressure circulating air heater is 1700-2000 Pa; the parameters of the circulating industrial air heater are as follows: 3-500 KW; maximum air volume: 1.8-75M3Min; wind pressure: 100 to 7500 pa; outlet temperature: normal temperature to 350 ℃; inlet temperature: normal temperature to 180 ℃; the device has the advantages of recycling, low heat loss, energy conservation, high efficiency, uninterrupted continuous work, durability and accurate temperature control.
3. And (3) demolding finished products: and (3) taking the mold out of the cavity when the temperature of the cavity is cooled to 125 ℃, taking the mold out when the temperature of the mold is reduced to 65 ℃, taking down the mold, dismantling the positioning pin, taking down the gland 3, and finally taking out the finished mattress (with the thickness of 80 mm).
Example 3
1. Fiber carding: before mixing, the low-melting-point fibers and the high-melting-point fibers are respectively carded by a fiber carding machine, wherein the adding weight of the low-melting-point fibers accounts for 20% of the total amount, and the adding weight of the high-melting-point fibers accounts for 80% of the total amount. The low-melting-point fiber is selected from the following brands: korean general korea (yinglong); the types are as follows: 4080 low melting fiber; melting point: 110 ℃; specification: 4D × 51 MM. The high melting point fiber is 40% of wool fiber and 60% of 7D 51 three-dimensional spiral polyester fiber.
2. Premixing: and putting the low-melting-point fibers and the high-melting-point fibers into an opening carding machine for opening, carding and mixing, and preparing the primary mixed cotton.
3. Heating and shaping: as shown in fig. 4, a pillow cushion mold (the mold comprises a base 1, a shell 2 and a gland 3, a plurality of vent holes are arranged on the base 1, the shell 2 is arranged on the base 1, the gland 3 is assembled in the shell 2, a handle 3-1 convenient to operate is arranged on the gland 3, a group of vent holes are arranged on the gland 3, the inner core of the mold is in a pillow cushion shape, mixed primary mixed cotton is put into the mold, the primary mixed cotton is compacted through the gland 3, then the gland is supported and compressed through a group of positioning pins (the positions of the positioning pins are arranged according to the thickness of the cushion, the positions of cushion positioning pins with different thicknesses are different), and then the mold is placed in a high-pressure circulating heat exchangerStarting a high-pressure circulating air heater at an air outlet of the fan, controlling the high-pressure circulating air heater to heat the cavity to 250 ℃ from the initial temperature for 1.5min, and then keeping the cavity at the temperature of 250 ℃ for 3min, wherein the whole shaping process is 4.5 min; the air pressure of the high-pressure circulating air heater is 1700-2000 Pa; the parameters of the circulating industrial air heater are as follows: 3-500 KW; maximum air volume: 1.8-75M3Min; wind pressure: 100 to 7500 pa; outlet temperature: normal temperature to 350 ℃; inlet temperature: normal temperature to 180 ℃; the device has the advantages of recycling, low heat loss, energy conservation, high efficiency, uninterrupted continuous work, durability and accurate temperature control.
3. And (3) demolding finished products: and (3) taking the die out of the cavity when the temperature of the cavity is cooled to 125 ℃, taking down the die when the temperature of the die is reduced to 65 ℃, removing the die, dismantling the positioning pin, taking down the gland 3, and finally taking out the finished pillow cushion (with the thickness of 30 mm).
Examples of the experiments
First, exploration of low melting point fiber and high melting point fiber ratio
1. High and low melting point fiber network forming proportioning test
TABLE 1
| Low melting fiber g | High melting fiber g | Quality: g | Tuyere temperature: c | Time: min | In the formed state |
| 20 | 180 | 200 | 200 | 5 | Soft |
| 40 | 160 | 200 | 200 | 5 | Is harder |
| 60 | 140 | 200 | 200 | 5 | Hard |
As can be seen from Table 1, the amount of the low-melting fiber added is controlled to be 10% to 30%, and the low-melting fiber added too much makes the product stiff.
Second, test of wind pressure, product thickness, temperature and time
1. Control group 1: when no wind pressure exists, the temperature is 140-180 ℃, a (common oven) high-melting point fiber network and a low-melting point fiber network are formed, and the test results of the product thickness, the temperature and the time are as follows:
TABLE 2
2. Control group 2: selecting wind pressure (1500Pa), selecting 140-180 ℃, forming a high-melting point fiber network and a low-melting point fiber network, and testing results of product thickness, temperature and time are as follows:
TABLE 3
3. Experimental groups: selecting wind pressure (1700Pa-2000Pa), selecting the temperature of 200-280 ℃, forming the high-melting point fiber network and the low-melting point fiber network, and obtaining the following test results of product thickness, temperature and time:
TABLE 4
Table 2 (wind pressure 1500Pa) compared with table 1 (no wind pressure), when the wind pressure is increased to 1500Pa, the product with the same thickness, when the same temperature is selected, the forming time is shortened by more than half;
table 3 compares with table 2, it can be seen that the whole forming process only needs 2-7min when the temperature is 200-280 ℃, wherein when the thickness of the product is 20mm and the temperature is 280 ℃, the whole forming time only needs 2min, and the forming effect is good. However, when the temperature is higher than 280 ℃ and the wind pressure is higher than 2000Pa, the high-melting-point fiber is melted, and the preparation of the fiber cotton pad is difficult.
In conclusion, the temperature of 200-280 ℃ is selected, and the wind pressure is 1700-2000Pa, the forming time of the fiber cotton pad is fast, and the forming effect is good.
The invention is not to be considered as limited to the particular embodiments shown, but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.
Claims (5)
1. The preparation method of the mixed fiber cotton pad is characterized by comprising the following steps:
step 1, premixing: putting low-melting-point fibers and high-melting-point fibers into an opening carding machine for opening, carding and mixing to prepare primary mixed cotton, wherein the melting point of the low-melting-point fibers is 100-130 ℃, the melting point of the high-melting-point fibers is 250-310 ℃, the adding weight of the low-melting-point fibers in the step 1 accounts for 10-30% of the total weight, and the adding weight of the high-melting-point fibers accounts for 70-90% of the total weight;
step 2, heating and shaping: put into the mould with the mixed cotton of above-mentioned primary type to compress tightly fixedly, then assemble the mould on high pressure cycle air heater, add the fever design to the mixed cotton of primary type in the mould, specifically do: the temperature of the cavity is heated to 200-280 ℃ from the initial temperature for 1-2min, then the temperature is kept at 200-280 ℃ for 1-5min, the whole shaping process is 2-7min, the air pressure of the high-pressure circulating air heater is 1700-2000Pa, and the shell of the die adopts a closed structure, so that hot air with pressure can only pass up and down, thereby ensuring that the high-pressure hot air penetrates through the middle and the low-melting-point fibers are fully melted and crosslinked;
step 3, demolding finished products: and (3) taking the mold out of the cavity when the temperature of the cavity is cooled to 115-125 ℃, demolding when the temperature of the mold is reduced to 55-65 ℃, and inspecting and warehousing after demolding of finished products.
2. The method for preparing the mixed fiber cotton pad as claimed in claim 1, wherein the air pressure of the high pressure circulating hot air blower in the step 2 is 1800-1900 Pa.
3. The method of making a mixed fiber cotton mat according to claim 1, wherein the high melting point fibers are one or more of chemical, animal natural fibers, and plant natural fibers.
4. The method of making a mixed fiber cotton mat as set forth in claim 1, wherein in step 1, the fibers are opened, carded and mixed separately by a fiber opening card before being mixed.
5. The method for preparing a hybrid fiber cotton mat according to claim 1, wherein in the step 2, the mold comprises a base, a shell and a gland, the base is provided with a hollow upright column at the center, the base is provided with a plurality of vent holes, the shell is mounted on the base, the periphery of the shell is of a closed structure, the gland is assembled in the shell, the gland is provided with a handle convenient to operate, and the gland is provided with a group of vent holes.
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